U.S. patent number 6,561,780 [Application Number 09/879,403] was granted by the patent office on 2003-05-13 for system and assembly for the manufacturing of prestressed reinforced concrete railroad ties and the like.
Invention is credited to David P. Ollendick, Robert W. Ollendick.
United States Patent |
6,561,780 |
Ollendick , et al. |
May 13, 2003 |
System and assembly for the manufacturing of prestressed reinforced
concrete railroad ties and the like
Abstract
Apparatus for the manufacturing of prestressed reinforced
concrete railroad ties and the like in which the apparatus consists
of an elongated spine or compression member which has no foundation
but rather is independent of the supporting surface upon which it
rests. In one version of the apparatus two bridge members confront
the opposite ends of the spine and permanent tension resisting
members pass beneath the spine from end to end of the spine and are
attached to the lower ends of the bridge members. In another
version two structural members are embedded in the concrete of the
spine and protrude to provide terminal members.
Inventors: |
Ollendick; David P. (San Ramon,
CA), Ollendick; Robert W. (Wickenburg, AZ) |
Family
ID: |
23514447 |
Appl.
No.: |
09/879,403 |
Filed: |
June 12, 2001 |
Related U.S. Patent Documents
|
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
420076 |
Oct 18, 1999 |
6374475 |
|
|
|
037803 |
Mar 10, 1998 |
|
|
|
|
383727 |
Feb 2, 1995 |
5747074 |
|
|
|
Current U.S.
Class: |
425/111; 264/228;
264/229; 425/123; 425/169 |
Current CPC
Class: |
B28B
23/043 (20130101); B28B 23/06 (20130101); B28B
17/0063 (20130101); Y10T 29/49874 (20150115); Y10T
29/49771 (20150115) |
Current International
Class: |
B28B
23/02 (20060101); B28B 23/04 (20060101); B28B
23/06 (20060101); B28B 023/06 () |
Field of
Search: |
;425/111,123,125,169,436R ;249/86 ;264/228,229 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
238960 |
|
Dec 1945 |
|
CH |
|
1024003 |
|
Oct 1952 |
|
DE |
|
3543369 |
|
Dec 1985 |
|
DE |
|
1357836 |
|
Oct 1972 |
|
GB |
|
1460149 |
|
Dec 1973 |
|
GB |
|
Primary Examiner: Davis; Robert
Assistant Examiner: Del Sole; Joseph S
Attorney, Agent or Firm: Foster; Lynn G.
Parent Case Text
CONTINUITY
This application is a continuation of our co-pending U.S. patent
application Ser. No. 09/420,076 filed Oct. 18, 1999, now U.S. Pat.
No. 6,374,475B1, which is a division of U.S. patent application
Ser. No. 09/037,803 filed Mar. 10, 1998, now abandoned which is a
continuation of U.S. patent application Ser. No. 08/383,727, filed
Feb. 2, 1995, now U.S. Pat. No. 5,747,074.
Claims
What is claimed is:
1. An assembly for use in the manufacturing of reinforced concrete
railroad ties, comprising: an elongated spine having opposed ends;
first and second apertured bridges respectively secured to said
spine in load transferring relation adjacent to the opposed end of
said spine, both of said bridges extending transversely beyond the
spine; at least one open top concrete mold; first and second
apertured anchors respectively disposed between the bridges and the
mold, the aperture in the bridges and the anchors being in
alignment, the anchors comprising end closures for the mold;
prestressing wires disposed within the mold and extending loosely
through the apertures in the anchors, each prestressing wire having
two ends, at least one end of at least some of the wires being
disposed between an associated bridge and anchor; a separate
adjustable tensioning coupler interposed between each one wire end
and the adjacent bridge, each coupler passing through one aperture
in the adjacent bridge and being fastened in said passing through
location.
2. An assembly according to claim 1 wherein a threaded shaft of
each coupler is disposed in the one associated aperture in the
adjacent bridge.
3. An assembly according to claim 2, a fastener is secured to each
threaded shaft beyond the associated bridge.
4. An assembly according to claim 1 wherein the at least one open
top mold comprises a plurality of concrete railroad tie molds.
5. An assembly according to claim 1 wherein at least some of the
couplers comprise a tension imposing device by which the tension is
imposed upon the associated wire can be individually and precisely
set.
6. An assembly according to claim 5 wherein at least some of the
tension imposing devices each comprise a tension read out
gauge.
7. An assembly according to claim 1 the spine comprising of a
plurality of separately fabricated modules which are joined
together in the end-to-end relationship.
8. An assembly according to claim 1 the spine comprising a
monolithic concrete structure.
9. An assembly for making a concrete reinforced railroad tie
comprising: at least one hollow mold comprising opposed
non-moveable apertured anchor plates, one at each end of the mold;
bridge abutments respectively spaced from the adjacent anchor plate
beyond the mold; a plurality of prestressing wires passing through
the mold and apertures in the anchor plates; an adjustable tension
applying coupler disposed in force transmitting relation between an
adjacent end portion of each wire and the adjacent bridge abutment
by which a control magnitude of tension is imposed separately upon
each wire.
10. An assembly according to claim 9 wherein the coupler comprises
a turnbuckle.
11. An assembly according to claim 9 wherein the coupler comprises
a fastener disposed beyond the associated bridge abutment.
12. An assembly according to claim 9 wherein the coupler comprises
a wire connector comprising a slot into which an enlarged end of
the wire is removably placed.
13. A system for making structural prestressed reinforced concrete
members comprising: a concrete spine entirely located above ground
or a floor; a mold superimposed above the spine, the mold having
first and second ends; an apertured plate contiguous with and
closing a mold end; an eccentric abutment aligned with but spaced
from each end plate; at least two wires disposed in the mold each
wire passing through a separate aperture in each end plate, each
wire comprising an end disposed between one mold end plate and the
adjacent abutment. a tension applying device interposed in load
transferring relation between each wire end and the adjacent
abutment, whereby a desired amount of tension is separately applied
to each wire by the associated tension applying device.
14. A system according to claim 13 further comprising a tension
gauge associated with each tension applying device by which the
amount of separately applied tension is ascertained.
15. A system according to claim 13 wherein each tension applying
device comprises a turnbuckle.
16. A system according to claim 13 wherein the wires loosely pass
through apertures in the mold end plates.
17. A system according to 13 wherein the spline comprises a series
of aligned concrete blocks.
18. A system according to claim 17 wherein the concrete blocks are
reinforced.
19. A system according to claim 13 wherein the spine is
balanced.
20. A system according to claim 13 wherein the spine is
unbalanced.
21. A system according to claim 13 wherein the spine comprises
monolithic concrete and steel.
22. A system according to claim 21 wherein the steel is selected
from the group consisting of internal reinforcing wires, external
structural members, end plates and intermediate plates.
23. A system according to claim 13 further comprising a mechanism
for lifting and dropping the mold with a cured concrete railroad
tie therein to dislodge the tie and at least one rail fastener from
the mold.
24. A system according to claim 13 further comprising alignment
guides carried by the spine upon which the mold is
superimposed.
25. A system according to claim 13 further comprising side rails
for displaceably receiving a straddle carrier above the mold.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to prestressed reinforced concrete
railroad ties and the like, and more particularly to methods and
apparatus for the manufacturing of prestressed reinforced concrete
railroad ties and the like.
2. Description of the Prior Art
Methods and apparatus for the manufacturing of prestressed
reinforced concrete railroad ties and the like are known in the
prior art.
For example, methods and apparatus for the manufacturing of
prestressed reinforced concrete railroad ties are disclosed in U.S.
Pat. No. 4,773,840, issued to Steven L. Jantzen on Sep. 27, 1988,
and entitled MANUFACTURE OF PRE-STRESSED CONCRETE RAILROAD
TIES.
Process and equipment for manufacturing pre-cast elements, made of
prestressed concrete, with immediate tensioning, in particular
prestressed concrete sleepers are disclosed in Patent Cooperation
Treaty Document PCT/EP93/00289.
A method of molding concrete ties or other similar articles having
prestressed reinforcing wires or rods therein is disclosed in U.S.
Pat. No. 4,051,216, issued to Robert Lyndon Bratchell on Sep. 27,
1977, and entitled IN-LINE MOLDING OF PRESTRESSED CONCRETE
ARTICLES.
A portable molding apparatus for prestressed concrete members, such
as concrete railroad ties, is disclosed in U.S. Pat. No. 3,577,613,
issued to William P. Hidden on May 4, 1971, and entitled PORTABLE
MOLDING APPARATUS.
An apparatus for forming prestressed concrete products is disclosed
in U.S. Pat. No. 3,666,385, issued to Robert S. Baker on May 30,
1972, and entitled APPARATUS FOR MAKING PRESTRESSED CONCRETE
MEMBERS.
A PORTABLE TENSIONING SYSTEM FOR PRODUCING PRE-STRESSED CONCRETE
BEAMS is disclosed in U.S. Pat. No. 4,149,306, issued to Ralph J.
Tice on Apr. 17, 1979.
APPARATUS FOR PRODUCTION OF REINFORCED CONCRETE PRECAST UNITS is
disclosed in U.S. Pat. No. 3,491,417, issued to Hans Haller and
Erwin Wendl on Jan. 27, 1970.
APPARATUS FOR PRODUCTION OF PRE-STRESSED MOLDED CONCRETE MEMBERS is
disclosed in U.S. Pat. No. 3,608,163, issued to Jon W. Harford on
Sep. 28, 1971.
Characteristically, some of the above-identified patents and other
documents disclose large, complex and extremely expensive
equipment, some of which equipment is completely lacking in
portability, requires special foundations, or must be located in a
specially provided building of large area.
It is believed that the documents listed immediately below contain
information which is or might be considered to be material to the
examination hereof.
U.S. Pat. No. 3,207,829
U.S. Pat. No. 3,182,948
U.S. Pat. No. 3,999,913
U.S. Pat. No. 3,685,934
British Patent Specification No. 1,357,836
British Patent Specification No. 1,460,149
German Laying Open Document No. 35 43 369
German Patent Publication 1 024 003
Swiss Patent 238960
It is to be understood that the term "prior art" as used herein or
in any statement made by or on behalf of applicants herein means
only that any document or thing referred to as prior art bears,
directly or inferentially, a date which is earlier than the
effective filing date hereof.
No representation or admission is made that any of the above-listed
documents is part of the prior art, or that no more pertinent
information exists.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide
apparatus for the manufacturing of prestressed reinforced concrete
railroad ties and the like, which apparatus are simpler and less
expensive than apparatuses of the prior art provided for the same
purpose.
Another object of the present invention is to provide apparatus for
the same purpose which is comprised in part of elements, sometimes
called "permanent elements", which are fabricated at a
manufacturing site, and left at that site, or disposed of near that
site when manufacturing operations at that site are permanently or
temporarily discontinued.
Yet another object of the present invention is to provide apparatus
for the above-stated purpose which is comprised of elements,
sometimes called "portable elements", which are moved from
manufacturing site to manufacturing site, and which may be
fabricated at a location or locations remote from these
manufacturing sites.
A further object of the present invention is to provide apparatus
for the above-stated purpose, which apparatus is aboveground
apparatus, i.e., does not require a foundation.
A further object of the present invention is to provide apparatus
for the above-stated purpose, which apparatus, during
manufacturing, need not be contained in a permanent building, but
rather may be contained in a temporary shelter such as a tent, or
may in certain climates be operated out of doors.
Another object of the present invention is to provide apparatus for
the above-stated purpose, which apparatus is equally adaptable to
the production of one prestressed reinforced concrete railroad tie
at a time or to the production of multiple prestressed reinforced
concrete railroad ties at a time.
A yet further object of the present invention is to provide
apparatus for the above-stated purpose, which apparatus includes
means for the provision of a report corresponding to each
individual product produced thereby, which report lists the tension
in each reinforcing element of the product during the curing of the
concrete mass of the product, or the maximum and minimum tension in
each reinforcing element of the product during the curing of the
concrete mass of the product.
Another object of the present invention is to provide apparatus for
the above-stated purpose wherein each reinforcing element
incorporated into each product is individually fully tensioned.
Yet another object of the present invention is to provide apparatus
for the above-stated purpose which minimizes wastage of reinforcing
element material.
A further object of the present invention is to provide apparatus
for the above-stated purpose, which apparatus can readily be
adapted to the production of reinforced concrete elements of many
different kinds, sizes and configurations.
A yet further object of the present invention is to provide
apparatus for the above-stated purpose, which apparatus can readily
be adapted to manufacture in existing buildings.
Another object of the present invention is to provide novel methods
for fabricating apparatuses for the manufacture of prestressed
reinforced concrete railroad ties and the like.
Yet another object of the present invention is to provide novel
methods for the manufacture of prestressed reinforced concrete
railroad ties and the like.
A further object of the present invention is to provide methods of
accomplishing the above-stated objects, which methods include the
step of fully tensioning each reinforcing element in a particular
product individually.
A yet further object of the present invention is to provide methods
of accomplishing the above-stated objects, which methods include
the steps of individually monitoring the tension in each
reinforcing element during the curing of a particular product and
providing a certificate setting forth the tension in each
individual reinforcing element during the curing of a particular
product.
Another object of the present invention is to provide methods of
accomplishing the above-stated objects, which methods include the
step of providing a certificate corresponding to each particular
product in which is tabulated the maximum and minimum tension in
each reinforcing element of that product throughout the curing of
that product.
Other objects of the present invention will in part be obvious and
will in part appear hereinafter.
The present invention, accordingly, comprises the several steps and
the relation of one or more of such steps with respect to each of
the others, and the apparatus embodying features of construction,
combinations of elements, and arrangements of parts which are
adapted to effect such steps, all as exemplified in the following
disclosure, and the scope of the present invention will be
indicated in the claims appended hereto.
In accordance with a principal feature of the present invention an
apparatus for the manufacturing of prestressed reinforced concrete
railroad ties is comprised of an elongated spine member which is
formed substantially entirely of concrete and has no
foundation.
In accordance with another principal feature of the present
invention said spine member, in a preferred embodiment of the
present invention, is composed of a plurality of mutually abutting
modules, each of which modules, is formed substantially entirely
from concrete.
In accordance with yet another principal feature of the present
invention said spine member, in another preferred embodiment of the
present invention, is a single, monolithic body of concrete.
In accordance with a further principal feature of the present
invention said spine member, in yet another preferred embodiment of
the present invention, is provided at its opposite ends with
abutment frame means which are deeply embedded in the concrete of
said spine member and which include abutment portions which project
from the upper surface of the concrete of said spine member and are
adapted to support anchor receiving means to which reinforcing
wires can be anchored.
In accordance with a yet further principal feature of the present
invention said spine member is provided with mold alignment guides
which are affixed to its top surface.
In accordance with another principal feature of the present
invention at least one end of each of said reinforcing wires is
anchored to one of said anchor receiving means by anchoring means,
which anchoring means includes a threaded rod passing through a
hole in said anchor receiving means and a nut engaged with said
threaded rod for adjusting the tension in its associated
reinforcing wire.
In accordance with yet another principal feature of the present
invention each of said anchoring means includes an intermediate
body interposed between said threaded rod and said reinforcing
wire, and a strain gauge coupled to said intermediate body for use
in measuring the tension in said reinforcing wire.
In accordance with another principal feature of the present
invention a bulbous protrusion or button is attached to an end of
said reinforcing wire and said anchoring means includes coupling
means which is adapted to receive said end of said reinforcing wire
and to prevent said protrusion from escaping from said coupling
means.
In accordance with a yet further principal feature of the present
invention the spine member of a balanced compression embodiment of
the present invention is provided with elevating means for
elevating it above the surface by which it is supported, said
elevating means defining, with said spine member, a passage which
extends beneath said spine member and substantially from end to end
thereof.
In accordance with another principal feature of the present
invention said balanced compression embodiment of the present
invention further includes first and second bridge means each of
which confronts one end of said spine member, projects above the
upper surface of said spine member, and confronts said passage.
In accordance with yet another principal feature of the present
invention at least one tension resisting member extends from end to
end of said passage and is affixed to the lower ends of said bridge
means.
In accordance with a further principal feature of the present
invention the upper ends of said bridge means are provided with
anchor receiving means whereby the opposite ends of reinforcing
wires can be anchored to said bridge means.
In accordance with a yet further principal feature of the present
invention the anchoring means attached to one of said anchor
receiving means comprises strain gauge means.
In accordance with another principal feature of the present
invention rails are provided on each side of said spine member,
which rails are adapted to support a straddle truck straddling said
spine member.
In accordance with yet another principal feature of the present
invention mold raising means are provided whereby the mold or molds
carried by said spine member can be raised from and lowered to the
upper surface of said spine member.
In accordance with a further principal feature of the present
invention certain preferred embodiments thereof include computer
means and printer means associated with all of the strain gauges
incorporated in said anchoring means and adapted to provide printed
reports of the tension in each of the reinforcing wires of a set of
reinforcing wires simultaneously mounted on the device of said
preferred embodiment.
In accordance with a yet further principal feature of the present
invention a method of manufacturing prestressed reinforced concrete
railroad ties comprises the steps of tensioning a set of
reinforcing wires between the ends of a single, aboveground spine
member, and individually adjusting the tension in each such
reinforcing wire.
In accordance with another principal feature of the present
invention said method of manufacturing prestressed reinforced
concrete railroad ties includes the step of printing a tabulation
of the tension in each individual reinforcing wire as measured by
strain gauges incorporated in one of the anchoring means associated
with each reinforcing wire.
For a fuller understanding of the nature and objects of the present
invention, reference should be had to the following detailed
description, taken in connection with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial perspective view of an apparatus for the
manufacturing of prestressed reinforced concrete railroad ties
embodying the present invention;
FIGS. 1A and 1B are partial perspective views of an alternate form
of an apparatus for the manufacturing of prestressed reinforced
concrete railroad ties embodying the present invention;
FIGS. 2 and 3 are partial perspective views of modules of the
apparatus of FIG. 1;
FIG. 4 is an enlarged perspective view of the anchoring means of a
particular embodiment of the present invention for anchoring
reinforcing wires to anchor receiving means thereof;
FIG. 5 is a partial perspective view of the apparatus of FIG. 1
having at least one railroad tie mold mounted thereupon and
reinforcing wires stretched in tension between the anchor receiving
means thereof;
FIG. 6 is a partial perspective view of a railroad tie mold and the
manner of its coaction with the mold alignment guides of the
apparatus of the invention;
FIG. 7 is a partial perspective view of two railroad tie molds
mounted upon an apparatus of the invention and having a complete
set of tension reinforcing wires passing therethrough;
FIG. 7A is a perspective view of a set of mold dividers of the kind
which may be interposed between the railroad tie molds mounted upon
an apparatus of the invention;
FIG. 8 is a partial perspective view of the spine of a balanced
compression railroad tie manufacturing apparatus of the present
invention;
FIG. 8A is a perspective view of a part of the apparatus of the
present invention shown in partial perspective view in FIG. 8;
FIG. 9 is an elevational view of one of the bridge members of the
apparatus of the present invention shown in part in FIG. 8;
FIG. 10 is a partial elevational view, partly in section, of the
apparatus of the present invention shown in partial perspective in
FIG. 8;
FIG. 11 is a partial elevational view of an apparatus of the
present invention, particularly showing the mold raising and
lowering apparatus which is a principal feature of the present
invention;
FIG. 12 is a partial sectional view of a railroad tie manufacturing
apparatus of a particular embodiment of the present invention,
including the rails provided for bearing a straddle truck which, in
accordance with the present invention, straddles the spine of said
apparatus;
FIGS. 13, 13A and 14 show further features of the mold raising and
lowering apparatus of the present invention;
FIGS. 15, 16 and 17 illustrate an apparatus for the manufacturing
of prestressed reinforced concrete railroad ties embodying the
present invention, and more particularly the apparatus of a second
balanced compression embodiment of the present invention;
FIG. 18 is a cross-sectional view of a typical prestressed
reinforced concrete railroad tie;
FIGS. 19 and 19A illustrate an array transforming device of the
present invention;
FIGS. 20 and 20A illustrate a reinforcing wire detensioning device
of the present invention; and
FIG. 21 is a schematic representation of the electronic data
conversion and printout means of certain embodiments of the present
invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, there is shown in part an apparatus 10
constructed in accordance with the present invention for use in the
manufacturing of prestressed reinforced concrete railroad ties.
As seen in FIG. 1, apparatus 10 is comprised of an elongated,
mutually abutting array of modules 12.1, 12.2, 12.3, etc., which
modules are joined together at their abutting faces to form a
single, elongated structural member 14 which is sometimes called
the "spine" herein.
The convention is adopted herein of designating all of said modules
in any apparatus 10 of the present invention, collectively, and
also of designating any individual one of said modules in general,
by the reference numeral 12. Thus, all of the modules 12.1 through
12.6 (FIG. 1) may sometimes be referred to as the "modules 12"
herein, and any one of the modules 12.1, 12.2, 12.3, etc., may
sometimes be referred to herein as "a module 12".
It is also to be understood that while the modules 12 shown in FIG.
1 are respectively designated by the reference numerals 12.1
through 12.6, apparatus 10 is not necessarily comprised of six
modules 12. Rather, apparatus 10 may in some embodiments of the
present invention be comprised of a sufficient number of modules 12
so that its total length is several hundred feet.
In keeping with the terminological practice of the art, an
apparatus 10 comprised of three or more modules 12 will sometimes
be referred to as a "long line".
On the other hand, it is also contemplated as part of the present
invention that certain embodiments of apparatus 10 may be comprised
of as few as two modules 12.
As will also be evident to those having ordinary skill in the art
from a comparison of FIGS. 1, 2 and 3, as described herein, there
are two classes of module 12, i.e., "terminal modules", such as
modules 12.1 and 12.6 shown in FIG. 1, and "intermediate modules",
such as modules 12.2, 12.3, 12.4, and 12.5, shown in FIG. 1.
A typical terminal module is more particularly described
hereinbelow in connection with FIG. 2; and a typical intermediate
module is more particularly described hereinbelow in connection
with FIG. 3.
As further seen in FIG. 1, each module 12 is principally comprised
of a solid, generally rectangular block of concrete; each of which
blocks is designated herein by a particular reference numeral,
e.g., 16.1, or by the general reference numeral 16, following the
same convention observed in connection with the designation of the
above-described modules.
As also seen in FIG. 1, the edges of the blocks 16 which are fully
exposed when the part of apparatus 10 shown in FIG. 1 is assembled
are protected by corresponding lengths of angle iron 18.
Referring now to FIGS. 2 and 3, it will be seen that a set of three
tubes 20, 20', 20" passes through each block 16 and extends
longitudinally from end to end thereof. The tubes 20, 20', 20"
(sometimes collectively designated by the reference numeral 20) in
each block 16 are suitably located in the mold when that block 16
is molded so that they will be located in the positions shown in
FIGS. 2 and 3, relatively to the bottom face and the outer vertical
faces of that block 16.
It is also to be noted from FIGS. 1, 2 and 3 that each of the tubes
20, 20', 20", i.e., the tubes 20, in every block 16 is so located
that when the blocks 16 of any apparatus 10 are aligned and joined
together as indicated in FIG. 1, all of the tubes 20 in that
apparatus will be aligned, all of the tubes 20' in that apparatus
will be aligned, and all of the tubes 20" in that apparatus will be
aligned.
Thus, as best seen in FIG. 1, a cable 22 extends through all of the
aligned tubes 20 from end to end of apparatus 10, a cable 22'
extends through all of the aligned tubes 20' from end to end of
apparatus 10, and a cable 22" extends through all of the aligned
tubes 20" from end to end of apparatus 10.
As also best seen in FIG. 1, a set of cable clamps 24, 24', 24" of
well known type are clamped to the ends of cables 22, 22', 22",
respectively, which project a short distance through the end 26 of
apparatus 10, and through a protective steel plate 27 which bears
against the exposed concrete face of end 26.
A suitable protective steel plate 27' is provided at the other end
of apparatus 10, i.e., abutting the exposed concrete face of the
exposed end of module 12.6.
A corresponding set of cable clamps 28, 28', 28" (not shown) are
clamped to the respective opposite ends of cables 22, 22', 22",
after suitably tensioning cables 22, 22', 22", and thus all of the
modules 12 of apparatus 10 are firmly joined together when the part
of apparatus 10 shown in FIG. 1 is fully assembled.
As best seen in FIGS. 2 and 3, a steel butt plate 30 is affixed to
each end of each intermediate module 12 (FIG. 3), and a single
steel butt plate 30 is affixed to the inner end of each terminal
module 12 (FIG. 2).
Butt plates 30 may be affixed to their corresponding ends of
modules 16 by being arc welded to the adjacent ends of abutting
edge protectors 18 before each frame comprised of butt plates and
their associated edge protectors is emplaced in the mold in which
the corresponding block 16 is to be molded.
As best seen in FIG. 3, each butt plate 30 is provided with two
ears 30', 30", each of which ears is provided with a pair of
bolt-receiving holes 32.
When modules 12 are aligned to form apparatus 10 (FIG. 1) each pair
of mutually confronting ears 30', 30" is joined together by bolts
passing through aligned pairs of holes 32, and associated nuts,
thus maintaining modules 12 in rigidly maintained, mutually joined
juxtaposition.
In accordance with well known practice, it may be found desirable
to interpose a layer of grout between butt plates 30, which grout
sets after modules 12 have been finally aligned.
As best seen in FIG. 3, eyes 34 are affixed to the edge protectors
18 of each intermediate module 12, as by arc welding. It is to be
understood that both of the upper edge protectors 18 of every
intermediate module 12 are provided with two eyes 18, at opposite
ends thereof, and that both of the lower edge protectors 18 of
every intermediate module 12 are provided with a single, centrally
located eye 34.
Referring again to FIG. 1, it will be seen that a single,
continuous cable 36 passes through all of the eyes 34 but the
outermost eyes 34', and is fastened to outermost eyes 34' by means
the provision of which is well within the scope of those having
ordinary skill in the art.
It is to be understood that a substantially identical cable 36'
coacts, in the same manner, with corresponding eyes 34' affixed to
the opposite sides of the intermediate modules 12 of apparatus
10.
Thus it will be seen that all of the intermediate modules 12 of
apparatus 10 are further securely joined together by means of two
cables 36, 36' one on each side of apparatus 10, coacting with the
eyes 34, 34' located on the opposite major vertical sides of spine
14 of apparatus 10.
Comparing FIGS. 1 and 2, it will be seen that in each of the
terminal modules 12.1, 12.6 of apparatus 10 there is embedded a
pair of triangular abutment frames 40.
As best seen in FIG. 2, each abutment frame 40 is fabricated from
heavy steel bar stock of rectangular cross-section, and the
separate legs thereof are joined together into a single, unitary
whole, as by arc welding.
As also seen in FIG. 2, a part 40' of each abutment frame projects
above the upper surface of concrete block 16.1. These projecting
portions 40' of abutment frames 40 will generally be called
"abutments" herein.
Thus, it will be understood that a pair of abutment frames 40 is
incorporated into each of the terminal modules 12.1, 12.6 of
apparatus 10 during the molding of the corresponding concrete
blocks 16.1, 16.6; and that each of these abutment frames 40
projects above the upper surface of its corresponding concrete
block 16.1, 16.6 to form an abutment 40'.
The spine 14 of apparatus 10 described hereinabove is of the type
designated herein as a "modular spine".
Referring now to FIG. 1A there is shown an alternative apparatus
50, constructed in accordance with the present invention, for use
in the manufacturing of prestressed reinforced concrete railroad
ties.
As seen in FIG. 1A, apparatus 50 is comprised of a monolithic,
solid concrete spine 52, which is formed as a single block 54 of
concrete, poured at the site at which apparatus 50 is to be used in
the manufacturing of prestressed reinforced concrete railroad
ties.
It is to be understood that it is a principal teaching of the
present invention that certain parts of apparatus of the invention
for use in the manufacturing of prestressed reinforced concrete
railroad ties (sometimes called "permanent parts" or "monosite
parts" herein) should be fabricated at the manufacturing site at
which they are to be used, while other more portable and generally
more complex and expensive parts of such apparatus (sometimes
called "portable parts" or "multisite parts" herein) should be
moved from manufacturing site to manufacturing site, leaving the
permanent or monosite parts at the manufacturing site at which they
are fabricated in contemplation of subsequent manufacture there, or
disposing of the permanent or monosite parts near the manufacturing
site at which they were fabricated.
Spine 52, then, would be such a permanent part, while modules 12
(FIG. 1) might be treated as either permanent parts or portable
parts, depending upon the availability of materials, cost of
fabrication, etc., at the respective intended manufacturing
sites.
Referring again to FIG. 1A, it will be seen that four abutments 56'
project from the upper surface of spine 52, two at each end
thereof.
As will be understood by those having ordinary skill in the art,
informed by the present disclosure, abutments 56' are projecting
parts of abutment frames 56, which are embedded in spine 52 during
its fabrication, in the same manner in which the abutment frames 40
of apparatus 10 (FIG. 1) are embedded in their corresponding
concrete blocks 16.1 and 16.6.
As will be clear to those having ordinary skill in the art,
apparatus 50 will sometimes hereinafter be called a "monolithic
spine embodiment" of the present invention, as distinct from
apparatus 10 (FIG. 1) which, as noted above, is sometimes called
herein a "modular spine embodiment".
Referring now to FIG. 1B, there is shown an apparatus 60 of the
present invention which is substantially identical to apparatus 50,
but for its length.
In accordance with the principles of the present invention
monolithic spine apparatus thereof may be made in any economically
feasible length, ranging from the "long line" version shown in FIG.
1A to the single tie version shown in FIG. 1B.
Comparing FIGS. 1, 1A and 1B, it will be seen that each of the
apparatuses depicted therein is disposed upon a support surface
which is designated by the same reference numeral as that assigned
to the apparatus itself, primed. Thus, the support surface under
apparatus 10 is designated by the reference numeral 10', the
support surface under apparatus 50 is designated by the reference
numeral 50', and the support surface under apparatus 60 is
designated by the reference numeral 60'.
It is thus to be understood that, in accordance with a principal
feature of the present invention, it is not necessary to provide an
inground foundation for a manufacturing apparatus of the present
invention. To the contrary, the manufacturing apparatus of the
present invention are aboveground apparatus, which are independent
from the support surfaces upon which they are disposed during tie
manufacturing. The only requirement for the supporting surface
underlying a manufacturing apparatus of the present invention is
that it be sufficiently solid and rigid to support the weight of
the apparatus and its associated equipment without deforming or
degrading.
Referring again to FIG. 1B, it will be seen that the spine 64 of
apparatus 60 thereof is a single, monolithic block of concrete.
It will also now be evident to those having ordinary skill in the
art, informed by the present disclosure, that each abutment 66'
shown in FIG. 1B is a projecting portion of a corresponding
abutment frame 66 which is embedded in concrete block 64 in the
same manner in which four abutment frames 56 are embedded in spine
52 of apparatus 50 to provide four abutments 56'.
Referring again to FIG. 1, it will be seen that a pair of mold
alignment guides 70, 70' are affixed to the top of spine 14, extend
from terminal module 12.1 to terminal module 12.6, and extend over
and are affixed to the top of each terminal module 12.1 and
12.6.
Guides 70 and 70' may be affixed to the upper faces of the modules
12 of spine 14 by means of studs projecting from the upper faces of
modules 12, the lower portion of each such stud being embedded in
its associated concrete block 16. In accordance with this
arrangement, the horizontal flange of each guide 70, 70' is
provided with holes adapted to receive the corresponding ones of
said studs, and nuts engaged with said studs and overlying said
horizontal flanges secure guides 70, 70' to the top of spine
14.
As seen in FIG. 1A, a pair of mold alignment guides 58, 58' are
affixed to the top of spine 52, preferably in the same manner in
which guides 70, 70' are affixed to the top of spine 14 (FIG.
1).
Similarly, a pair of mold alignment guides 68, 68' are affixed to
the top of spine 64 (FIG. 1B).
Referring again to FIG. 1, it will be seen that a terminal plate 76
is affixed to its associated abutments 40, 40', and that a terminal
plate 76' is affixed to its associated abutments 40, 40'.
As best seen in FIG. 2, which is an enlarged view of terminal
module 12.1, terminal plate 76 is affixed to its associated
abutments 40' by means of bolts 78, the threaded ends of which
bolts are engaged in tapped holes in the vertical members of
associated abutments 40'.
It is to be understood that terminal plate 76' (FIG. 1) is affixed
in the same manner to its associated abutments 40', 40'.
As also seen in FIG. 2, terminal plate 76 is provided with an array
80 of holes, each of which holes is adapted to receive a terminal
end of one of the anchoring assemblies by which one end of a
reinforcing wire or rod is anchored during the manufacture of a
prestressed reinforced concrete railroad tie by means of apparatus
10.
While, for clarity of illustration, array 80 shown in FIG. 2 is an
essential uniform rectilinear array, it will be understood by those
having ordinary skill in the art that the usual reinforcement array
in a typical prestressed reinforced concrete railroad tie is
somewhat irregular, as is the typical array 80' shown in FIG. 18,
and there related to the cross-sectional outline of the tie 80" of
which the wires of the array 80' are a part.
Referring now to FIG. 4, there is shown a part of terminal plate
76, one of the tapped holes 78' for receiving the threaded end of
one of the bolts 78 (FIG. 2), some of the holes of array 80 (FIG.
2), and one of said anchoring assemblies. Each of said anchoring
assemblies may be designated herein by the general reference
numeral 82.
Correspondingly, the holes of array 80 will collectively be
designated herein by the reference numeral 84, and any single hole
of array 80 may be designated by the reference numeral 84, where it
is not necessary or desirable to designate a particular hole 84 of
array 80.
Where, however, it is desirable to designate a particular hole of
array 80, or a particular corresponding anchoring assembly or
reinforcing wire, the convention will be adopted herein of
individually designating each hole in array 80, etc., by the
corresponding column designating letter and row designating number
in array 80 as viewed from beyond the end of apparatus 10 shown at
the left-hand side of FIG. 1, and also shown in full at the
left-hand side of FIG. 2.
As best seen in FIG. 2, the holes 84 of array 80 will be considered
to be arrayed in vertical columns A through F, and in horizontal
rows 1 through 3.
Thus, it will be seen that the upper left-hand hole in array 80
(FIG. 2) may be uniquely designated by the designator 84A1.
Similarly, the lower right-hand hole 84 in array 80 (FIG. 2) may be
uniquely designated by the designator 84F3; and the third hole from
the left-hand end of the middle row of array 80 (FIG. 2) may be
uniquely designated by the designator 84C2.
The associated individual anchoring assemblies and reinforcing
wires will be designated by designators having the same column and
row designators as those of their associated holes 84.
Thus, the anchoring assembly 82 shown in FIG. 4 may be uniquely
designated by the designator 82F1, and the reinforcing wire
anchored at one of its ends by anchoring assembly 82F1 (FIG. 4) may
be uniquely designated by the designator 86F1.
Referring again to FIG. 4, it will be seen that anchoring assembly
82F1 consists of a first threaded rod 90, a nut 92, an elongated
hexagonal nut 94 of the kind sometimes called a "rod coupler", a
strain gauge 96 which is affixed to elongated nut 94 in the well
known manner, e.g., by cementing, a second threaded rod 98, and a
coupler 100.
Coupler 100, which is a principal feature of the present invention,
is comprised of a steel frame 101 having a nut 102 affixed to one
of the smaller sides 104 thereof, in alignment with a hole passing
through side 104, and a slot 106 in the other end thereof which is
adapted to receive one end of associated reinforcing wire 86.
As indicated in FIG. 4, nut 92 is engaged with the threads of
threaded rod 90 which passes through hole 84F1. The other end of
threaded rod 90 is threaded into the tapped passage of nut 94.
Threaded rod 98 is threaded into the other end of the tapped bore
of nut 94, and is also threaded into nut 102.
As also indicated in FIG. 4, the end of reinforcing wire 86 shown
in that figure is provided with a bulb 86', as by braising a nut or
sleeve thereon, in accordance with a principal teaching of the
present invention, and is then dropped into slot 106 of coupler
100, bulb 86' passing through the enlarged end 106' of slot
106.
In accordance with a principal feature of the present invention,
the threads of rod 90, nut 92 and nut 94 are of the Acme or
buttress-type, and the buttress-type threads, when used, are
oriented for maximum force and wear qualities in the direction
producing tension in reinforcing wire 86, i.e., with the face of
the thread making the greatest angle with the axis of the thread
facing reinforcing wire 86. In this manner, the life of threaded
rod 90 and nuts 92 and 94 is extended as much as possible.
As will now be evident to those having ordinary skill in the art,
informed by the present disclosure, each end of each reinforcing
wire 86, during the production of one or more prestressed
reinforced concrete railroad ties by apparatus 10, is anchored at
each end by means of an anchoring assembly substantially identical
to the anchoring assembly 82 described immediately above, half of
these anchoring assemblies 82 being engaged with the arrayed holes
in terminal plate 76 (FIG. 1), and the other half of these
anchoring assemblies being engaged with the holes in terminal plate
76' (FIG. 1).
As will become evident hereafter to those having ordinary skill in
the art, each apparatus of the present invention is provided at its
opposite ends with different reinforcing wire anchoring assemblies.
For example, nuts 94 and strain gauges 96 (FIG. 4) need be provided
at only one end of any apparatus of the invention. At the opposite
end of the same apparatus each threaded rod 90, bearing nut 92, may
pass through its associated hole 84' in terminal plate 76', and
then be threaded into the nut 102 of its associated coupler
101.
Thus, for clarity, the end of any apparatus of the present
invention which includes the strain gauges will be called the
"first end" or "instrumented end" thereof, and the other end of the
same apparatus of the present invention will, correspondingly, be
called the "second end" or "uninstrumented end".
Referring now to FIG. 5, there is shown the first or instrumented
end of the apparatus of FIG. 1, at that stage of the manufacturing
of a plurality of prestressed concrete railroad ties when a full
set of reinforcing wires 86 have been anchored at their respective
ends and correctly tensioned, and just prior to the filling of the
associated molds 120 with concrete.
As also seen in FIG. 5, a plurality of tie molds 120, only the
first one of which, 120-1, is shown, are emplaced on mold alignment
guides 70, 70'.
Mold 120-1 is provided with an end plate 124-1, which is affixed to
the outer end of mold 120-1 by means of suitable bolts 126.
As seen in FIG. 6, the outer end 120-1' of mold 120-1 is provided
with a plurality of threaded cylindrical inserts 128 which are
adapted to receive and engage bolts 126.
End plate 124-1 is provided with an array of holes 130 which
correspond in array geometry to the holes 84 in terminal plate 76.
Holes 130 are of sufficient size to accommodate the bulbs 86' of
the reinforcing wires 86, but closely surround each reinforcing
wire 86, whereby to minimize the leakage of concrete from mold
120-1.
It is to be understood that a substantially identical end plate
124-2 is bolted to the outer end of the mold which is located at
the opposite end of mold alignment guides 70, 70'.
Referring now to FIG. 7, there is shown the gap 134 between tie
mold 120-1 and adjacent tie mold 120-2. In accordance with a
principal feature of the present invention this gap may be as
little as 1/2 inch, thereby affecting considerable reinforcing wire
cost savings as compared with prior art methods and apparatus for
the manufacture of prestressed reinforced concrete railroad
ties.
Also shown in FIG. 7 is the divider 136 which is placed between
molds 120-1 and 120-2 after wires 86 and molds 120 have been
positioned on apparatus 10 as shown in FIG. 7. In the known manner,
the slots 136' in divider 136 receive the respective wires 86 of
the vertical columns A through F (not lageled).
It is to be understood that a similar divider will be positioned
between each adjacent pair of tie molds 120 arrayed on guides 70,
70' of apparatus 10.
Referring now to FIG. 7A, there is shown an alternative form of
divider 140 which may be used instead of divider 136 shown in FIG.
7.
As will be evident to those having ordinary skill in the art,
informed by the present disclosure, element 140-1 will then be
located immediately below horizontal array 86A3 through 86F3 of
wires 86 in FIG. 7; element 140-2 will be located between
horizontal arrays 86A3 through 86F3 of wires 86 and horizontal
array 86A2 through 86F2 of wires 86; element 140-3 will be located
between horizontal array 86A2 through 86F2 of wires 86 and
horizontal array 86A1 through 86F1 of wires 86; and element 140-1
will extend vertically from the wires of horizontal array 86A1
through 86F1 to the top edge of molds 120-1 and 120-2.
It is to be understood that the apparatuses of the present
invention may be considered to be divided into two types, viz., the
unbalanced compression type, as shown in FIGS. 1 through 7A, and
the balanced compression type as shown in FIGS. 8 through 10 and 15
through 17.
The distinction between these two types of devices of the present
invention can be seen, for example, by comparing FIGS. 2 and
10.
As there seen, the devices of the unbalanced compression type of
device resist the forces produced by the tension in the wires
tensioned thereby only by the resistance of the spine (e.g., spine
14) to being ruptured by the breaking of the abutment frames 40 out
of the spine 14; whereas in the devices of the second or balanced
compression type (FIG. 10) the forces produced by the wires 86,
under tension, are balanced by the compressive forces produced by
the heavy counterbalancing rod elements (e.g., 246, 246') located
below the spine.
In FIGS. 8 through 10 there is shown an apparatus 200 of the
present invention for use in manufacturing prestressed reinforced
concrete railroad ties which is of the balanced compression
type.
Referring now to FIG. 8, there is shown one end of spine 202 of
apparatus 200, to which a reinforcing plate 204 is affixed by means
of bolts 206, which extend into cylindrical threaded inserts in
spine 202, the recessed heads of bolts 206 only being shown in FIG.
8.
It is to be noted that a transverse rib 208 projects outwardly from
the main body of reinforcing plate 204, and that a plurality of
studs 210 are provided on plate 204 for a purpose which will be
explained hereinafter.
It is also to be noted that spine 202 is provided with longitudinal
flange-type legs 212, 212'.
Spine 202 is a monolithic concrete member the length of which is
determined by the number of tie molds which are to coact therewith,
and a reinforcing plate 204' substantially identical to reinforcing
plate 204 is affixed to the opposite end of spine 202.
It is to be understood that the term "monolithic" as used herein
does not denote a concrete member consisting solely of concrete,
but rather denotes a unitary concrete member, whether reinforcing
rods or the like are included therein or not.
Comparing FIGS. 9 and 10, it will be seen that apparatus 200
further comprises a bridge member 220 having a pair of ribs 222,
224 which closely embrace rib 208 of plate 204 when apparatus 200
is assembled.
As seen in FIG. 9, bridge 220 is provided at its upper end with an
array of holes 228 which are arrayed in an array similar to the
reinforcing rod array of the railroad ties which are to be
manufactured by means of apparatus 200.
Bridge 220 (FIG. 9) is also provided, at its lower end, with a pair
of holes 230 the purpose of which will be explained
hereinafter.
Referring again to FIG. 10, it will be seen that spine 202 is
provided with mold alignment guides 232, 232' similar to guides 70,
70' shown in FIG. 1, and having the same purpose.
Apparatus 200 also includes four L-brackets 234, having a pair of
elongated holes 236 in one branch thereof.
As see in FIG. 10, all four brackets 234 are secured to plate 204
by means of studs 210 (FIG. 8) and their associated nuts 240.
L-brackets 234 serve to grasp the end of spine 202, thus preventing
transverse shifting of plate 204 when it is being attached to spine
202.
As further seen in FIG. 10, a pair of countertension rods 246, 246'
extend from end to end of spine 202, passing between legs 212, 212'
thereof.
Countertension rods 246, 246' are secured to bridges 220, 220'
located at opposite ends of spine 202, by means of bolts 248, 248'
located at the end of apparatus 200 shown in FIG. 10 and bolts 248"
and 248'" located at the opposite end of spine 202.
Comparing FIGS. 9 and 10, it will be seen that a set of eighteen
anchoring assemblies 258 are engaged with corresponding holes 228
in bridge 220 in the same manner in which anchoring assemblies 82
are engaged with terminal plate 76 in FIG. 4. Each anchoring
assembly 258 is comprised of a threaded rod 260, a nut 262, an
elongated hexagonal nut 264 to which is affixed a strain gauge 266,
a second threaded rod 268, and a coupler 270 with which the end of
a reinforcing wire 272 having a bulb 272' at its end is engaged.
The parts of each anchoring assembly 258 are substantially
identical to the corresponding parts of the anchoring assembly 82
shown in FIG. 4.
When referred to any particular one of said anchoring assemblies
258, or any particular part of one of said anchoring assemblies,
the convention for designating individual anchoring assemblies,
etc., set out hereinabove in connection with array 80, etc., is
also adopted in the present discussion of anchoring assemblies 258.
Thus, the anchoring assembly shown at the top of FIG. 10 will
sometimes be designated by the designator 258F1 herein, and the
anchoring assembly shown at the bottom of the array seen in FIG. 10
will be designated by the designator 258F3.
Referring now to FIG. 12, there is shown a partial cross-sectional
view of a monolithic spine embodiment of the present invention.
Concrete spine 278 not only has a main body 280 and flange legs
282, 282', as in the first balanced compression-type embodiment of
the present invention shown and described herein (FIGS. 8, 8A, 9
and 10), but also includes railbed wings 283, 283' and retarding
ribs 284, 284'. It is to be understood also that spine 278 may have
embedded in it reinforcing means for reinforcing either the railbed
ribs 283, 283', or the retarding wings 284, 284', or both. Mold
alignment guides 286, 286' will also be affixed to the top of spine
278.
As also seen in FIG. 12, a pair of rails 290, 290' are affixed to
the respective tops of railbed wings 283, 283'.
Rails 290, 290' are adapted to bear a straddle truck generally
designated by the reference numeral 292, the flanged wheels of
which ride on the respective rails 290, 290'.
Straddle truck 292 is provided for the purpose of carrying the
concrete supply means by which molds borne by guides 286, 286' are
filled; concrete vibrators; lifting and handling equipment for
lifting and handling molds, reinforcing wires, completed ties,
etc.
It is to be understood as a principal feature of the present
invention that rails 290, 290' may not only extend along spine 278,
but also may extend throughout the yard or plant, i.e., the
facility, in which apparatus 296 embodying spine 278, etc., and in
some cases other apparatus of the same kind, are located.
Referring again to FIG. 12, it will be seen that, as a feature of
the present invention, straddle truck 292 is provided with calliper
clamps 297, 297', operated by handles 298, 298' to selectively
frictionally grasp retarding ribs 284, 284', whereby straddle truck
292 can be locked in any desired position along spine 278.
Referring now to FIGS. 11, 13, 13A and 14, there are illustrated
certain methods and apparatus of the present invention whereby the
well known problem of handling rail fasteners during the
manufacture of prestressed reinforced concrete railroad ties is
solved, at least in part.
As is well known to those having ordinary skill in the art, rail
fasteners are incorporated into modern concrete railroad ties by
partial embedment of these rail fasteners into the upper faces of
these railroad ties (known as "sleepers" in areas outside the
United States).
For this purpose, i.e., for the incorporation of rail fasteners
into concrete railroad ties, these ties are molded in their
inverted state, with the upper surface of each tie being formed by
the bottom of the mold.
Thus, in the general practice of the prior art before the teachings
of the present invention, the rail fasteners for each tie were
deposited in suitable mounts fixedly located in the bottom of the
mold, before the filling of the mold with concrete.
While this practice resulted in the firm embeddment of the rail
fasteners in the tie, considerable difficulty was sometimes
encountered in removing the completed ties from the molds without
damaging the tie or the bond between one or more fasteners and the
tie body, due to the tendency of the concrete to cause the inserted
rail fasteners to become adhered to the mold.
In accordance with a principal feature of the present invention,
means are provided as part of certain apparatus of the present
invention whereby individual molds can be slightly raised from the
top of the spine of the apparatus and maintained in that slightly
elevated position during the filling of the molds with concrete and
the curing of the concrete, whereafter, the ties being cured in
their molds, the respective molds are slightly dropped, and thus
the rail fasteners, which are supported by small bosses mounted in
the spines of the apparatus, remain embedded in the ties, which are
now parted from their associated molds, and thus the rail fasteners
are separated from their associated molds without damage to the
molded ties or to the bonds between the molded ties and their
associated rail fasteners.
Referring now to FIG. 11, then, there is shown in part the
apparatus 50 of the present invention (FIG. 1A) modified to
incorporate the specialized apparatus of the present invention
whereby the abovedescribed method of the present invention is
carried out.
As seen in FIG. 11, apparatus 10 includes an elongated monolithic
concrete block 54 (FIG. 1A).
Also seen in FIG. 11, a tie mold 300 and parts of two adjacent tie
molds 299, 301 are disposed upon the mold alignment guides 58, 58'
(FIG. 1A), only the front edge of the horizontal flange of guide 58
being visible in FIG. 11.
As further seen in FIG. 11, two transverse recesses 302, 304 each
extend from side to side of spine 54 and to the top thereof, in
such manner that guides 58, 58' pass over these recesses and, where
they pass thereover, are unsupported by spine 54.
A recess 302' is located at and joined with transverse recess 302,
and a recess 304' is located at the opposite end of and joined with
transverse recess 304.
As will be seen in FIG. 11, major recesses 302, 304 extend
completely through spine 54, but minor recesses 302', 304' do
not.
It is to be understood that each recess 302', 304' is matched by a
corresponding recess of the same kind which extends inwardly from
the opposite major vertical face of spine 54. Recess 302' is shown
in detail in FIG. 14 and discussed hereinbelow in connection with
FIG. 14.
As also seen in FIG. 11, two ribs or tracks 306, 306' are raised
upon the floor of recess 302, and extend completely from wall 308
to wall 308' of recess 302. Another pair of ribs 310, 310' are
raised upon the floor of recess 304, and extend completely from
wall 312 to wall 312' thereof. Each rib 306, 306', 310, 310' is
located below the position occupied by the rail fasteners when they
are properly located in the bottom of mold 300.
Movable support blocks 318, 318' are slidably mounted,
respectively, on ribs 306 and 306', each block 318, 318' defining a
groove in which its associated rib 306, 306' is received.
Similarly, movable support block 320, 320' are slidably mounted,
respectively, on ribs 310 and 310', each block 320, 320' defining a
groove in which its associated rib 310, 310' is received.
Thus, it will be seen that each one of the four support blocks 318,
318', 320, 320' is longitudinally slidable (parallel to the plane
of FIG. 11) from sidewall to sidewall of the transverse recess in
which it is located, but is not movable laterally, i.e.,
perpendicularly to the plane of FIG. 11.
Two cylindrical bosses 322, 324 project from the top surface of
support block 318, and two cylindrical bosses 322', 324' project
from the top surface of support block 318'.
Each boss 322, 324, 322', 324' is provided at its upper end with an
adaptor adapted to receive and hold a rail fastener, with each such
fastener extending through a close-fitting opening in the bottom of
mold 300.
Similarly, two cylindrical bosses 326, 328 project from the top
surface of support block 320, and two cylindrical bosses 326', 328'
project from the top surface of support block 320'.
Each boss 326, 328, 326', 328' is provided at its upper end with an
adaptor adapted to receive and hold a rail fastener, with each such
fastener extending through a close-fitting opening in the bottom of
mold 300.
Thus, it will be seen that by means of the apparatus located in
transverse recesses 302, 304, as discussed immediately above, the
rail fasteners which are to be incorporated in the tie which is to
be molded in mold 300 can be supported in the correct position for
embedment in the concrete in mold 300 when the bottom of mold 300
is located in the raised position indicated by the dashed line
300'(FIG. 11).
It will be seen by those having ordinary skill in the art, informed
by the present disclosure, that when mold 300 is raised to the
position indicated by dashed line 300, said rail fasteners are
passed through said close-fitting openings and seated in said
adapters, and mold 300 is filled with concrete, which is then
allowed to cure, all of said rail fasteners will be correctly
located in the concrete of the resulting tie body in mold 300.
If, then, mold 300 is dropped downwardly, below the position
indicated by dashed line 300', the concrete tie body, and the rail
fasteners, will be supported on bosses 322, 322', 324, 324', 326,
326', 328, and 328', and by the reinforcing wires passing
therethrough which wires are also supported by dividers 140-1,
140-2, 140-3 (FIG. 7A).
Simple methods and apparatus for thus raising and lowering mold
300, which methods and apparatus are principal features of the
present invention, are illustrated in FIG. 14.
As there shown, a simple lever 330 can be inserted into recess
302', for example, with its short arm 330.1 contacting the bottom
of mold 300 (FIG. 14), and the stub 330.2 of its long arm 330.3
received in recess 332 in floor plate 334 of recess 302'.
When four of such levers as lever 330 are thus emplaced in the four
recesses 302', 304', etc., associated with mold 300, and
simultaneously operated by four laborers, mold 300 can be raised to
the extent indicated by dashed line 300' (FIG. 11), and four
corresponding shims 336 (FIG. 14), etc., can be inserted between
the horizontal flanges of guides 58, 58' and the bottom of mold
300, thus maintaining mold 300 in its raised position indicated by
dashed line 300' until said four levers are again used to remove
shims 336, etc. When said shims are thus removed, mold 300 will
drop away from the completed tie, leaving said rail fasteners
properly embedded in the just molded tie.
As seen in FIGS. 13 and 13A, a more sophisticated arrangement may
be used to thus raise and lower mold 300.
In this case, lever 348 is removably fitted to one end of a pivot
rod 350, the square end of pivot rod 350 and the corresponding
square opening in the lower end of lever 348 nonrotatably fixing
lever 348 to pivot rod 350.
As seen in both FIGS. 13 and 13A, pivot rod 350 passes through a
transverse tube which extends from major face to major face of
spine 54 and is embedded therein.
Two cams 352, 352' are nonrotatably affixed to pivot rod 350, and
thus when lever 348 is manually operated from its solid line
position to its dashed line position (FIG. 13), one end of mold 300
is raised by the amount of the rise of cams 352 and 352'.
As seen in FIG. 13, lever 348 can be operated from stop 354 to stop
356.
Since lever 348 is over center when it is in contact with stop 356,
lever 348 will then remain in its dashed line position until
manually operated toward stop 354, and thus mold 300 will remain in
its raised position until lever 348 is manually operated toward
stop 354.
Referring to FIG. 13A, which is a view from the opposite side of
spine 54 from that shown in FIG. 13, it will be seen that pivot rod
350 and its associated pivot rod 358, which is located at the other
end of mold 300 and carries two cams 360, 360' similar to and
serving the same function as cams 352, 352 cooperate to raise and
lower mold 300. It will be seen by those having ordinary skill in
the art, informed by the present disclosure, that when pivot rods
350 and 358 are turned in opposite directions as indicated by
arrows 362, 364 (FIG. 13A), all four cams 352, 352', 360, 360',
will coact to raise mold 300.
As will be evident to those having ordinary skill in the art,
informed by the present disclosure, cable 368, which is oppositely
wound on pulleys 370, 372, and is affixed to each pulley by clamps
operated by screws 366, 368, causes pulleys 370, 372 to operate in
the mutually opposed directions shown by arrows 362, 364, or both
in the opposite direction, and that thus the operation of lever 348
will be seen to cause mold 300 to rise or fall as discussed above.
Other means, such as hydraulic cylinder means, may alternatively be
used to raise and lower mold 300, all within the scope of the
present invention.
Referring now to FIGS. 15, 16, and 17, there is shown an apparatus
400 of a second preferred embodiment of the balanced compression
type apparatus of the present invention.
Referring now to FIG. 15, there is shown in part the spine 402 of
apparatus 400.
To the end of spine 402 which is shown in FIG. 15, a reinforcing
plate 404 is affixed by means of bolts 406 which extend into
cylindrical threaded inserts in the monolithic concrete body 408 of
spine 402, the recessed heads of bolts 406 only being shown in FIG.
15.
It is to be noted that reinforcing plate 404 is plane faced, as
compared with reinforcing plate 204 in the first preferred balanced
compression embodiment shown in FIG. 8, which is provided with a
transverse rib 208.
It is also to be noted that body 408 is provided with longitudinal
flange-type legs 410, 410'.
Spine body 408 is a monolithic concrete member the length of which
is determined by the number of tie molds which are to coact
therewith, and a reinforcing plate 404' substantially identical to
reinforcing plate 404 is affixed to the opposite end of spine body
408.
The term "monolithic" as used in the description of this second
preferred embodiment of the balanced compression type of the
apparatus of the present invention is to be understood to have the
same denotation set out hereinabove in the description of the first
preferred embodiment of the balanced compression type of apparatus
of the present invention.
Comparing FIGS. 15 and 17, it will be seen that apparatus 400
further comprises a bridge member 412 which is of open frame
construction as best seen in FIG. 16.
As may be seen by comparison of FIGS. 16 and 17, bridge member 412
is comprised of two vertical frame members 414, 416 which are
joined together by four cross members 418, 420, 422, 424, all of
which are permanently joined to vertical frame members 414, 416, as
by arc welding.
A pressure plate 426 spans vertical members 414, 416 and is
permanently joined thereto, as by arc-welding.
As best seen in FIG. 16, an array 434 of holes 436 passes through
upper terminal plate 428, which is fixed to vertical members 414,
416.
Further, a pair of larger holes 440 passes through lower terminal
plate 430, which is fixed to vertical members 414, 416.
It is to be understood that array 434 of holes 436 is an array
similar to the reinforcing rod array of the railroad ties which are
to be manufactured by means of apparatus 400.
In what follows, the individual holes 436 and their associated
reinforcing wires, etc., are designated in accordance with the same
convention which is explained hereinabove in detail in connection
with FIGS. 4 and 5.
Thus, in FIG. 16, the upper left-hand hole in terminal plate 428 is
particularly designated by the designator 436A1, and the third hole
from the left in the middle row of holes in terminal block 428 is
designated by the designator 436C2.
As further seen in FIG. 17, a set of eighteen anchoring assemblies
450 are engaged with corresponding holes 436 in terminal plate 428
in the same manner in which anchoring assemblies 82 are engaged
with terminal plate 76 in FIG. 4. Each anchoring assembly 450 is
comprised of a threaded rod 452, a nut 454, an elongated hexagonal
nut 456 to which is affixed a strain gauge 458, a second threaded
rod 460, and a coupler 462 with which the end of a reinforcing wire
464 having a bulb 464' at its end is engaged. The parts of each
anchoring assembly 450 are substantially identical to the
corresponding parts of the anchoring assembly 82 shown in FIG.
4.
Referring now to FIGS. 19 and 19A, there is shown an array
transformer device of the present invention which may be used when
necessary or desirable to increase the separation between the
reinforcing wire tension adjustment nuts of any particular
apparatus of the present invention, such as the tension adjusting
nuts 92 of the embodiment of the present invention shown in FIGS.
1, 2, 3, 4, 5, 6, 7 and 7A.
As best seen in FIG. 5, the tension adjusting nuts of a particular
embodiment of the present invention may be located very close to
each other, and thus may require the provision of specialized
equipment to rotate the individual nuts in order to produce the
specified tension in each reinforcing wire of a tie being produced
by that apparatus.
It may be, then, that certain reinforcing wire arrays required by
tie specifications issued by certain railroads or transit
authorities may necessitate the use of an array transformer such as
shown in FIGS. 19 and 19A.
Referring again to FIGS. 19 and 19A, there is shown an array
transformer 500 of the present invention.
It is assumed that array transformer 500 is applied to the
apparatus of the present invention shown in FIGS. 1, 2, etc., and
that array transformer device 500 is thus substituted for terminal
plate 76 in FIG. 2.
Thus, it will be seen that array transformer 500 is bolted to
abutments 40' by means of bolts 502, which pass through suitable
holes in the ears 504 of transformer device 500, and are then
received in tapped holes in abutments 40'.
It is to be understood that transformer 500 is comprised of a
closed housing 506 which consists of a set of steel plates 508,
510, 512, 514, 516, etc., which are bolted together to form housing
506. In addition to ears 504, housing 506 may be provided with one
or more legs or struts 516 by means of which housing 506 is rigidly
positioned with respect to the remainder of the apparatus of FIGS.
1, 2, etc.
As may be seen by comparison of FIGS. 19 and 19A, a plurality of
rigid rods 520 are fixedly positioned within housing 506.
An array of holes 522 corresponding to the reinforcing wire array
of the railroad tie to be produced, but with considerably larger
interspacing than the reinforcing wires in the railroad tie to be
produced, pass through plate 512 of housing 506.
A plurality of holes 524 arrayed in an array which is substantially
identical to the specified array of reinforcing wires in the
railroad tie to be produced pass through segmented wall plate 514
of housing 506.
A threaded rod 530 provided with a nut 532 passes through each of
the holes 522 in wall plate 512 of housing 506.
A coupler 534 generally resembling coupler 101 shown in FIG. 4, but
somewhat shorter, is secured to the inner end of each threaded rod
530 by means of an associated nut 536.
Each coupler 534 is attached to one end of a coupling cord 540 by
means of a bulb 540' integrally molded or cemented to one end of
coupling cord 540.
Each coupling cord 540 is fabricated from a cord of well known
plastic material the tensile strength of which is several times the
tensile strength of steel, such as Kevlar, which is used in
critical applications such as that of automobile tire cords.
Plate 514 is segmented into elongate members which are coupled
together by vertical rods in close-fitting holes (not shown), and
holes 524 are defined between said elongate members, one half of
each hole in one of said elongate horizontal members, whereby plate
514 can be disassembled for the replacement of one or more of
coupling cords 540.
As seen in FIG. 19, then, the inner end of each coupling cord 540
passes through one of said holes 524, and is then affixed to a
corresponding coupler 544 by means of its end bulb 540".
Each coupler 544 is joined to a threaded rod 546 in the manner in
which the corresponding coupler 534 is joined to its associated
threaded rod 530.
Each threaded rod 546 is joined to an elongated hexagonal nut 548
in the manner shown in FIG. 4, and described hereinabove in
connection therewith.
In the manner described hereinabove in connection with FIG. 4, each
elongated hexagonal nut 548 is provided with a strain gauge
549.
A threaded rod 550 is threaded into the end of each elongated
hexagonal nut 548 remote from housing 506, and a coupler 552 is
affixed to the opposite end of each threaded rod 550 by means of a
nut which is welded to the yoke or frame of each coupler in the
manner indicated in FIG. 4, and described in connection
therewith.
The reinforcing wires 86 which are to be incorporated in the
railroad ties to be produced are then fastened to their individual
associated couplers 552 by means of their terminal bulbs 86', in
the manner disclosed hereinabove in connection with FIG. 4.
As shown in FIG. 19A, rods 520 guide coupling cords 540 from the
smaller array of holes 524 to the larger array of holes 522,
without obstructing the passage of the bulbs 540' of cords 540
through housing 506.
Thus, it will be seen that array transformer 500 makes it possible
to locate tensioning nuts 532 sufficiently far apart so that each
nut is readily accessible to a socket-type torque wrench, and the
complete plurality of tensioning nuts 32 may be serviced by a gang
tensioner consisting of a plurality of rigidly mutually juxtaposed
socket-type torque wrenches, or the like.
Referring now to FIGS. 20 and 20A, there is shown a detensioning
device 600 which is a feature of the present invention.
While the reinforcing wire tension adjusting nuts of the apparatus
of the present invention (e.g., nuts 92, FIG. 5) may be used to
move together their reinforcing wire coupling devices at their
respective ends of the apparatus of the present invention
sufficiently to permit new reinforcing wires to be installed, it
may in some apparatuses be desirable to provide means which avoid
such extensive operating of the tension adjusting nuts in order to
avoid wear of the tensioning nuts and their associated threaded
rods. Detensioning device 600 is such a means.
As best seen in FIG. 20, detensioning device 600 is assumed to be
adapted to apparatus 10 of the present invention, in lieu of the
tensioning plate 40' located at the second or uninstrumented end
thereof.
As seen in FIG. 20, detensioning device 600 is comprised of a
closed housing 602 one end of which is disposed upon module 12.6,
and is affixed to the two abutments 40' located at that end of
apparatus 10 by means of suitable bolts and tapped holes (not
shown).
A movable terminal plate 604 is slidably mounted in housing 602,
and the ends of a plurality of threaded rods 606 are maintained in
a suitable array of holes passing through movable terminal plate
604 by means of associated nuts 608.
As will now be evident to those having ordinary skill in the art,
informed by the present disclosure, each threaded rod 606 is
provided with a coupler of the kind shown in FIG. 4, and an
associated reinforcing wire is affixed to the opposite end of each
such coupler in the manner indicated in FIG. 4.
A rigid horizontal positioning rod 610 (FIG. 20) is coupled to
terminal plate 604 by means of a yoke 612 (FIG. 20) which permits
access to all of the nuts 608.
As seen in FIG. 20A, a differential screw and toggle mechanism 620
of well known type, often employed in older toggle presses, is
mounted in housing 602.
A typical mechanism of this type is shown and described in the book
"Mechanisms, Linkages, and Mechanical Controls", edited by Nicholas
P. Chironis, and published by the McGraw-Hill Book Company, Inc.,
in 1965, at page 155.
As there explained, this mechanism provides increasing mechanical
advantage as nuts 622, 622' approach each other.
As also seen in FIG. 20A, the moving output block 624 of mechanism
620 is rigidly coupled to rod 610 by means of a yoke comprised of
upper and lower members 626, 628, which are coupled to each other
and to rod 610 by a vertical crosspiece 630.
Thus, it will be evident to those having ordinary skill in the art,
informed by the present disclosure, that by rotating handwheel 632
an operator of the apparatus may move tensioning plate 604 (FIG.
20) in either direction, and thus may either move the reinforcing
wire couplers affixed to threaded rods 606 to the left as shown in
FIG. 20, thus permitting the easy insertion of the ends of
reinforcing wires into the couplers associated with threaded rods
606, or, by rotating hand wheel 532 in the opposite direction, may
forcefully draw terminal plate 604 to the right as shown in FIG.
20, thereby producing sufficient tension in all of the reinforcing
wires so that only small changes need be made in the tensions of
the individual reinforcing wires by means of the tensioning nuts
located at the opposite end of apparatus 10.
Referring now to FIG. 21, there is shown the reinforcing wire
tension reading and recording apparatus 700 which is a principal
feature of the present invention.
Reading and recording apparatus 700 is comprised of a converter
unit 702 which is provided with a number of input jacks 704 equal
to the number of strain gauges employed in a particular
corresponding apparatus of the present invention.
Each cable 704A1, 704A2 . . . 704F2, 704F3, is plug-connected to an
associated input jack 704 of converter 702, and contains four
electrically independent conductors.
Thus, as will be evident to those having ordinary skill in the art,
each input jack 704 of converter 702 is connected to the four
terminals of an associated bridge-type strain gauge. Converter 702
applies a voltage to two terminals of each bridge-type strain gauge
via two conductors of its associated cable, and receives a signal
proportional to the momentary tensile force experienced by that
strain gauge via the other two conductors thereof.
It is to be understood, however, that the present invention does
not exclusively contemplate the use of bridge-type strain gauges,
and that thus other strain gauges of well known type may be used,
and coupled to a suitable associated converter 702.
It is further to be noted that the present invention is not limited
to the employment of the particular type of strain gauge shown
herein, e.g., in FIG. 4, but rather, in different embodiments, may
utilize any available type of commercial strain gauge suited to the
purpose.
As also indicated in FIG. 21, converter 702 is linked to a computer
706, and cooperates with computer 706 to display on the display
screen 708 of computer 706 a tabulation of the currently existing
tension in each reinforcing wire held in tension between the two
terminal plates of the associated railroad tie manufacturing
apparatus of the present invention.
For this purpose, computer 706 supplies to converter 702, on line
710, a clock signal which is used in coordinating the action of
converter 702 with the operation of computer 706.
Cable 712 serves to transfer from converter 702 to computer 706 a
series of signals representing the tensile forces in the respective
reinforcing wires tensioned between the terminal plates of the
associated apparatus of the present invention.
In accordance with a principal feature of the present invention, a
printer 714 which is driven by computer 706 serves to provide, for
each set of ties produced by the associated apparatus of the
invention, a printed certificate 716 tabulating the tension in each
reinforcing wire at some time during the curing of the concrete of
the resulting railroad tie.
It is also a feature of the present invention to so program
computer 706 that certificate 716 tabulates the maximum and minimum
tension experienced by each reinforcing wire at any time during the
curing of a particular set of railroad ties.
By way of example, each Kevlar coupling cord 540 shown in FIG. 19
may be provided with a sylphon or bellows, the closed end of which
is cemented or otherwise affixed to the cord and the open end of
which is adapted to be airtightly secured to a single plate 514,
the holes 524 being of sufficient diameter to freely admit the
bulbs 540' of the coupling cords 540, whereby to prevent the
incursion of dust and moisture into housing 506.
By way of a further example, a vertical partition may be provided
in the detensioning apparatus 600 of the invention shown in FIG.
20, which partition contains a packing gland through which rod 610
passes, whereby to prevent the incursion of dust and moisture into
the chamber containing differential screw and toggle mechanism
620.
Further, it is to be understood that the mold raising and lowering
mechanism, the array transformer mechanism and the detensioning
mechanism of the invention may, or all or any of them, may be used
in an apparatus embodying any of the spine constructions of the
present invention shown and described herein.
It will thus be seen that the objects set forth above, among those
made apparent from the preceding description, are efficiently
attained, and since certain changes may be made in the above
constructions and the methods carried out thereby without departing
from the scope of the present invention, it is intended that all
matter contained in the above description or shown in the
accompanying drawings shall be interpreted as illustrative only,
and not in a limiting sense.
It is also to be understood that the following claims are intended
to cover all of the generic and specific features of the invention
hereindescribed, and all statements of the scope of the invention
which, as a matter of language, might be said to fall
therebetween.
* * * * *